System and method for manufacturing a customized orthopedic support pillow

Abstract

The technology discloses an orthopedic support pillow tailored to a user's anatomy. The method involves capturing multiple images of a user's head and neck from different angles using a camera system. A three-dimensional (3D) digital twin of the user's head and neck is then generated using computer-aided design (CAD). The manufacturing process includes providing a wedge of pillow material, which is then molded based on the generated 3D digital twin and results in a depression on the wedge's surface. The dimensions of the wedge correspond to that of the 3D digital twin.

I/We claim: 
     
         1 . A method for manufacturing an orthopedic support pillow, the method comprising:
 receiving multiple images of a user's head and the user's neck generated by a camera system,
 wherein the multiple images depict contours of the user's head and the user's neck, and 
 wherein each of the multiple images is taken at a different angle to each other of the multiple images; 
   performing computer-aided design (CAD) to generate a three-dimensional (3D) digital twin of the user's head and the user's neck,
 wherein a depth of the 3D digital twin corresponds to a depth of a depression in the orthopedic support pillow shaped and sized to support the user's head and the user's neck, 
 wherein a width of the 3D digital twin corresponds to a lateral dimension of the user's head, and 
 wherein a length of the 3D digital twin corresponds to a longitudinal dimension of the user's head, and 
 wherein the generated 3D digital twin is configured to be used in molding a resilient material to manufacture the orthopedic support pillow; 
   providing a wedge of the resilient material,
 wherein the wedge of the resilient material comprises a base, a top, and an inclined surface connecting the base and the top, 
 wherein the base includes a first side, a second side, a third side, and a fourth side, 
 wherein a first distance between the base and the top of the wedge forms a pillow height of the wedge of the resilient material, 
 wherein a second distance between the first side and the third side of the base forms a pillow width of the wedge of the resilient material, and 
 wherein a third distance between the second side and the fourth side of the base forms a pillow length of the wedge of the resilient material; and 
   molding, based on the generated 3D digital twin, a depression into a surface of the wedge of the resilient material,
 wherein an angle formed by the inclined surface and the base is selected based on the 3D digital twin so that the pillow height is greater than the depth of the 3D digital twin, 
 wherein the pillow height is greater than the width of the 3D digital twin, 
 wherein the pillow length is greater than the length of the 3D digital twin; 
 wherein the depression is positioned between the base and the top of the wedge for supporting the user's head and the user's neck, and 
 wherein dimensions of the depression correspond to the dimensions of the 3D digital twin. 
   
     
     
         2 . The method of  claim 1 , wherein the resilient material comprises soy-based foam. 
     
     
         3 . The method of  claim 1 ,
 wherein generating the 3D digital twin uses mesh reconstruction techniques to refine the 3D digital twin,   wherein the mesh reconstruction techniques consider for surface irregularities.   
     
     
         4 . The method of  claim 1 , wherein generating the 3D digital twin uses selective laser sintering and/or fused deposition modeling. 
     
     
         5 . The method of  claim 1 , wherein the resilient material comprises memory foam, latex, polyurethane foam, gel-infused foam, bamboo foam, natural fibers, high-resilience foam, and/or natural latex foam. 
     
     
         6 . The method of  claim 1 ,
 wherein the wedge of the pillow material comprises an additional layer,   wherein the additional layer comprises a different pillow material than the wedge.   
     
     
         7 . The method of  claim 1 , wherein the wedge of the resilient material has a U-shape or circular shape. 
     
     
         8 . A system for manufacturing an orthopedic support pillow, the system comprising:
 a camera system for capturing multiple images of a user's head and the user's neck,
 wherein the multiple images depict contours of the user's head and the user's neck, and 
 wherein each of the multiple images is taken at a different angle to each other of the multiple images; 
   a processing module for determining dimensions of a three-dimensional (3D) digital twin of the user's head and the user's neck;
 wherein a depth of the 3D digital twin corresponds to a depth of a depression in the orthopedic support pillow shaped and sized to support the user's head and the user's neck; 
   a generation module for performing computer-aided design (CAD) to generate the 3D digital twin of the user's head and the user's neck,
 wherein the generated 3D digital twin is configured to be used in molding a pillow material to manufacture the orthopedic support pillow, 
   a wedge of the pillow material,
 wherein the wedge of the pillow material comprises a base, a top, and an inclined surface connecting the base and the top; and 
   a molding module for molding, based on the generated 3D digital twin, a depression into a surface of the wedge of the pillow material,
 wherein an angle formed by the inclined surface of the wedge is selected based on the 3D digital twin so that a pillow height of the wedge is greater than the depth of the 3D digital twin, and 
 wherein dimensions of the depression correspond to the dimensions of the 3D digital twin. 
   
     
     
         9 . The system of  claim 8 , comprising a user interface configured to receive user input associated with the 3D digital twin. 
     
     
         10 . The system of  claim 8 , wherein the wedge of the pillow material is foldable and/or collapsible. 
     
     
         11 . The system of  claim 8 , wherein the wedge of the pillow material includes an adjustable air chamber configured to be inflated and/or deflated to adjust dimensions of the wedge of the pillow material. 
     
     
         12 . The system of  claim 8 ,
 wherein the wedge of the pillow material comprises an additional layer,   wherein the additional layer comprises a different pillow material than the wedge.   
     
     
         13 . The system of  claim 8 , wherein said molding uses a vacuum-forming process, a rotational molding process, water-assisted injection molding process, extrusion molding process, and/or gas-assisted molding process. 
     
     
         14 . The system of  claim 8 , comprising an integrated lumbar roll on one end of the wedge of the pillow material. 
     
     
         15 . An orthopedic support pillow, comprising:
 a wedge of a pillow material;   a depression molded into a surface of the wedge of the pillow material based on a 3D digital twin;
 wherein the 3D digital twin is generated by:
 capturing multiple images of a user's head and the user's neck with a camera system,
 wherein the multiple images depict contours of the user's head and the user's neck, and 
 wherein each of the multiple images is taken at a different angle to each other of the multiple images; 
 
 performing computer-aided design (CAD) to generate a three-dimensional (3D) digital twin of the user's head and the user's neck,
 wherein the generated 3D digital twin is configured to be used in molding the pillow material to manufacture the orthopedic support pillow, 
 wherein dimensions of the 3D digital twin are based on the multiple images of the user's head and the user's neck, 
 
 
 wherein an angle formed by the wedge is selected based on the 3D digital twin so that a height of the wedge is greater than a depression depth of the 3D digital twin, and 
 wherein dimensions of the depression correspond to the dimensions of the 3D digital twin; and 
   an outer cover,
 wherein the outer cover is comprised of a different material than the pillow material, 
 wherein the outer cover is configured to envelop the wedge of the pillow material. 
   
     
     
         16 . The orthopedic support pillow of  claim 15 , wherein the outer cover comprises a moisture-wicking material, preventing accumulation of moisture. 
     
     
         17 . The orthopedic support pillow of  claim 16 , wherein the outer cover comprises a heating element to raise a temperature of the outer cover. 
     
     
         18 . The orthopedic support pillow of  claim 15 , comprising an attachment system that is configured to attach cooling elements, heating elements, and/or massaging elements to the wedge of the pillow material. 
     
     
         19 . The orthopedic support pillow of  claim 15 ,
 the wedge of the pillow material comprises of individual sections to be replaced and/or adjusted independently for targeted support for the user's head and/or the user's neck.   
     
     
         20 . The orthopedic support pillow of  claim 15 , wherein the wedge of the pillow material incorporates variable firmness zones,
 wherein the variable firmness zones include firm regions and soft regions for predetermined areas of the user's head and/or the user's neck.